This manual covers the 2001 SX, MXC, and EXC models, available in 250, 400, 450, 520, and 525cc variants. These motorcycles are recognized for their strong off-road racing heritage and performance-oriented motorcycles. These models are known for their potent four-stroke engines, advanced suspension systems, and competitive chassis, making them highly regarded machines for motocross and enduro riding. The engineering quality and reliability of these Austrian-manufactured motorcycles have contributed to their success in various racing championships. This comprehensive service repair manual provides detailed information for full service, repair, maintenance, and restoration. It covers all major systems, including engine overhaul, transmission, chassis, electrical systems, brakes, and bodywork. The manual includes step-by-step repair instructions, diagnostic procedures, troubleshooting guides, and detailed illustrations. It is designed to assist professional technicians, experienced DIY enthusiasts, and owners in maintaining and repairing their motorcycles, offering a level of detail equivalent to or exceeding many OEM service manuals. 🏷️ Basic Information Identification Make: KTM Model: SX, MXC, EXC Model Variants: 250, 400, 450, 520, 525 Year: 2001 👋 Introduction Market Position Target Audience: Professional technicians, experienced DIY enthusiasts, and owners seeking comprehensive repair knowledge Competitive Analysis Comparison To Oem: Provides equivalent or superior detail to many OEM service manuals, often more accessible. Key Features Accessibility: Instant download eliminates shipping costs and waiting times. Comprehensiveness: Covers all aspects of repair, maintenance, and diagnostics for the specified models. Usability: Well-structured with clear instructions, illustrations, and troubleshooting aids. 📋 Manual Details Coverage Areas Primary Coverage: Full Service, Repair, Maintenance, Rebuild, Restoration Technical Disciplines: Diagnostics, Troubleshooting, Electrical Service, Mechanical Repair Page Count Estimated Page Count: Not specified (assumed comprehensive for full service) Manual Type Type: Full Service Repair Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download System Requirements: Adobe PDF Reader, WinRAR Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine: Complete overhaul, internal components, lubrication system, cooling system, fuel system (carburetor and injection systems if applicable) Transmission: Gearbox disassembly, assembly, clutch operation, shift mechanism Chassis: Frame inspection and repair, suspension (front and rear), steering system, wheels and tires Electrical: Ignition system, lighting, charging system, starting system, wiring diagrams, troubleshooting electrical faults Bodywork: Fairings, plastics, seat, fuel tank removal and installation Brakes: Hydraulic system, caliper maintenance, pad replacement, master cylinder service Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service Repair: Detailed step-by-step repair instructions for all major components Troubleshooting: Diagnostic procedures for common and uncommon issues, fault finding guides Rebuild: Complete engine and transmission rebuild procedures Restoration: Guidance for refurbishing and restoring the motorcycle to original specifications Technical Depth Depth: Professional level, suitable for experienced technicians and advanced DIY mechanics Detail Level: Detailed sub-steps, notes, cautions, and warnings for critical information Visuals: Detailed illustrations, drawings, photos, and enlarged inset diagrams Electrical Diagrams: Combined with troubleshooting and service procedures 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Storage Options: Can be saved to hard drive or burned to CD-ROM. Print Quality Printability: Full Printable (all pages) Binding Type Binding: Digital (no physical binding) Paper Type Paper: Not applicable (digital format) File Organization Navigation: Numbered table of contents for fast information retrieval ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder (likely for all variants, with variations in displacement) Engine Displacements: 250cc, 400cc, 450cc, 520cc, 525cc (specific engine code per variant would be in manual) Performance Power Output: Detailed power and torque figures for each engine variant (specifics to be found within manual) Cooling System: Liquid-cooled (typical for SX/MXC/EXC models of this era) Fuel System Fuel Delivery: Carburetor (likely Dell'Orto or Keihin, specifics in manual) Fuel Type: Unleaded gasoline (specific octane rating in manual) Lubrication Oil Type: High-quality motorcycle-specific engine oil (e.g., Motorex, specific viscosity and API rating in manual) Oil Capacity: Specific oil capacity for each engine variant (detailed in manual) 🔧 Transmission Standard Type: 6-speed constant mesh manual transmission Optional Options: Not typically applicable for this model range Features Clutch: Hydraulically operated multi-plate wet clutch (specific details on operation and maintenance in manual) Gear Ratios: Specific gear ratios for each model variant provided in manual 📐 Dimensions Exterior Frame Type: Chromium-molybdenum steel central-tube frame (typical for KTM) Wheelbase: Specific wheelbase dimensions for each model variant provided in manual Weights Dry Weight: Varies by model (e.g., 250SX around 100-105kg, larger models slightly more; specifics in manual) Fuel Tank Capacity: Typically around 7-9 liters (specifics in manual) 🛡️ Safety Features Ratings Safety Ratings: Not applicable for off-road motorcycles in traditional crash test ratings. Active Features Braking System: Hydraulic disc brakes front and rear (brand likely Brembo, specific caliper and rotor specs in manual) Suspension Control: Adjustable front forks (WP) and rear monoshock (WP PDS system common) for tailored handling and stability. 💡 Technology Features Infotainment Features: Basic, functional design focused on performance. No complex infotainment systems present. Driver...